Stackable, thin-walled containers

ABSTRACT

A liquid container for a comestible product such as milk or juice includes a base having a substantially planar region, a top surface having a substantially planar region parallel to the substantially planar region of the base and having a pour spout. A sidewall is integrally formed with and extends between the base and top surface, and includes a structural load distributing feature that transfers loads from the top surface to the base. A handle is interposed between the base and top surface and integrally formed with the base, top surface, and sidewall. The containers can be arrayed into units and stacked on top of one another. A first flexible material such as a shrink wrap holds the individual containers together and a second flexible material maintains the stacked array of containers together so that cases that typically hold the containers can be eliminated.

RELATED APPLICATIONS

This application claims the benefit of U.S. provisional application Ser.No. 60/052,775, filed Jul. 1, 1997.

BACKGROUND OF THE INVENTION

The present invention relates generally to receptacles and containerstructures. Specifically, the invention relates to molded, thin-walledcontainers that are capable of being stacked upon one another forstorage and shipping purposes. For the purpose of clarification,caseless shipping is the ability to deliver products in a shippingcontainer which requires no returnable, disposable, or replaceablecases.

To develop the concept of thin-walled containers an exemplary containerwill be used to reference thin-walled containers and establish a workingdefinition that can be described, for example, as a ratio of the amountof plastic resin required to make a container relative to the amount ofproduct capable of being transported in the container. To illustrate theconcept, an industry standard gallon milk container should be used asthe reference container for the development of the concept. Typicalbottle weights for this container range from 90 grams (at the time thebottle was first introduced back in 1952) to 56 to 60 grams (asmanufacturing technology progressed to today's standards).

In the field of art relating to the shipping and storage of bulk foodproducts including milk and beverages, plastic molded containers areused to contain the products for transport, distribution, and ultimatelyfor dispensing by consumers. Known containers usually take the form ofblow-molded, one-piece plastic containers. The pour opening defines theuppermost wall or surface of the container and is generally located atthe center of the container. A tapering region extends downwardly fromthe pour spout merging with four sidewalls that are disposed insubstantially perpendicular relation relative to one another. A handleis integrally molded in the container and has a generally invertedL-shape. A first leg of the handle extends generally horizontally fromthe tapering region and a second leg of the handle extends generallyvertically, merging with a sidewall junction of the container just abovea base.

These containers are typically stored and shipped in some form ofshipping case; consequently, these containers have been designed withlittle regard to the structural loading, stackability, and efficientpackaging during transport. Unitized cases contain between four to sixcontainers and take several different forms such as wire or plasticcases, corrugated boxes, or corrugated materials which providestructural support to the individual containers during shipping. Theseunitized cases are shown in FIGS. 1A (corrugated boxes) and 1B (plasticcases).

FIGS. 2A-2C illustrate several delivery mechanisms which are capable ofshipping a large number of full containers which may or may not beunitized in cases. A brief description of the above shipping mechanismswill assist in further defining the principle of thin-walled, caselessshipping. Pallets (FIG. 2A) that support stackable cases are the mostwidespread form of shipping product for the retail or food serviceindustry and the cases are the only returnable, reusable shippingmechanism considered by the industry. Bossies (FIG. 2B) and dollies(FIG. 2C) are primarily utilized by the dairy industry and areconsidered large, mechanical cases. There is a large cost associatedwith bossies and dollies since they have to be returned, cleaned, andreused in a similar fashion as the pallet cases.

For further discussion, the caseless concept will be defined on thepallet shipping mechanism as described below.

Cases can be stacked on pallets in several different configurationsbased on the pallet footprint. Typical pallets will have approximatelytwo-hundred to two-hundred-fifty containers shipped on them and will bestacked from four to six cases high depending on the pallet size. Theforces associated with these cases is evident from a consideration ofthe weight of a three liter milk container that is approximately six toseven pounds (or approximately eight and one-half pounds per gallon).The structure and strength of these cases make them ideal for stackingthin-walled containers that carry a dense product, however, their usehas been problematic. The actual case costs are relatively inexpensiveand are intended to be reused with a typical life of two years; however,the cases are often misappropriated by vandals or thieves for use inother applications, i.e., as storage containers for different articles.

The cost associated with cases really occurs at the manufacturingfacility and during distribution.

To understand the impact of caseless shipping in manufacturingfacilities using cases, it is important that an appreciation of thecurrent method for casing product be attained. The majority of the dairyindustry uses plastic cases to some significant measure if they do notuse them exclusively. The basic cycle of a case is as follows:

Cases are purchased for a price of approximately $2.00 (sixteen quartcase) and are entered into the already large inventory of cases on an asneeded basis. Even in the best operations, this replenishment process isdriven by damage, new business, theft, customer accumulation, etc. Insome instances, this replacement initiative is quite extensive anddemands a significant portion of management time in order to maintaincontrol of the case supply.

During a typical production day, cases must be continually fed to thefacility as product is produced. This requires several people dedicatedto move and unload trailers of empty cases as they return from theroutes and one person dedicated to ensure that a continual supply ofcases are maintained during production hours. In addition, large,covered areas are needed to house empty cases which requires maintenanceand upkeep. Inventory costs associated with these cases need to beconsidered and can be rather extensive based on the size of the dairy.FIGS. 3 and 4 illustrate some of the space requirements associated withcases. After the cases are unloaded and start through the productionprocess, the cases must be destacked in the proper orientation to beprepped for container filling.

FIGS. 5A and 5B illustrate a typical destacker system. The maintenancefees for this system have a percentage impact on the cost of goods.Continual supervision is required to ensure the destacker does not jamor prevent cases from flowing to the next pre-production stage.

Cases are then moved to the case cleaning system in which extremelycaustic cleansers wash and clean the cases prior to container filling.The cleansers affect cost to the system by increasing sewer bills,replacement and maintenance of the equipment and expensive cleansers.FIG. 6 illustrates typical case washing equipment.

The cases are then conveyed to the filling process. The cases are loadedthrough automatic casing equipment and combined into stacks of five orsix case heights. These stacks are conveyed into refrigerated areaswhere they are placed into storage positions for later retrieval asillustrated in FIGS. 7A-7C.

Distribution costs also impact on the costs associated with shippingthese containers. Hooking, track shipping, or automated materialhandling systems are several methods for storing and retrieving filledcases. These methods are illustrated in FIGS. 8A-8D such as using hooksto pull cases (FIG. 8A), track shipping (FIG. 8B), using a pallet jack(FIG. 8C), and it should be noted that the automated material handlingsystems (FIG. 9) require large superstructures to house the casedproduct and are very capital intensive.

The containers are then shipped by various means in these cases.Depending on the system, the customer, and the demand, the containerswill be pulled from various storage systems by the techniquesillustrated above and loaded onto a distribution vehicle for delivery toa customer.

Depending on the type of distribution business considered, distributionexpense may range from being very important to the most important issuein succeeding in a business. For a distributor, food service, orwholesaler who manufactures no products, the warehousing anddistribution costs are likely the most crucial to the success of thebusiness. Operational efficiencies depend on excelling in these areas.As a result, warehouses and distribution methods have been designed toreturn only the industry standard pallets. Reluctantly, and withsubstantial costs, many distributors handle product in cases with hopesthat a corrugated alternative may become cost effective in the future.Smaller, more service-oriented distributors clearly recognize the valueof eliminating returnable cases as the delivery person becomes much moreefficient resulting from the elimination of non-value adding activities.

As stated above, the primary method for many customers to receiveproduct is primarily on pallets or cases stacked on the floor. Thoughother variations exist, the fundamental economics are associated withthese two methods.

Depending on the size of the customer, a typical trailer may have one totwelve customer orders to be delivered. The orders are loaded on thetrailer in by stop sequence. A driver's typical delivery day isdescribed below. The first customer will be delivered and the productwill be taken to the cooler. Empty cases will be loaded onto pallets andwrapped with tape or shrink wrap to maintain a stable load. Thesepallets are then loaded into the back of the truck to be returned to theproduction facility at the end of the route as illustrated in FIG. 10.

The driver then departs to deliver to the next customer. One of twosolutions occur. First, if the trailer was completely loaded such thatthere was very little room, the driver will have to unload the emptycases he just loaded at the previous stop before he can begin to deliverthe next customer. Alternatively, if the trailer is partially full, thedriver may have sufficient room to work and may not have to rotate emptycases until later stops. It should be noted that the practice ofmaximizing trailer loads to the back door is the norm to minimizedistribution costs. The above empty case rotation is continued until allproduct is delivered and all of the empty cases are collected.

The critical steps for case delivery are summarized below:

1. Drive to the stop

2. Unload product for delivery

3. Load empty cases

4. Drive to stop

5. Unload empty cases

6. Unload product for delivery

7. Load new and old empty cases and/or rotate load

8. Drive to stop

9. Repeat until load is complete

It is envisioned that caseless shipping would have enormous benefits andlabor savings associated with, for example, the distribution, thecritical steps for delivery are summarized below:

1. Drive to stop

2. Deliver purchases material

3. Pick up pallet(s)

4. Drive to next stop

5. Deliver purchased material

6. Pick up pallet(s)

7. Repeat until load is complete

The difference is the lack of non-value services required. As isrealized, there is no wasted time collecting empty cases or rotatingproduct and empty cases on the trucks. Other obvious savings are betterutilization of trailer loads because no space needs to be allocated forcases and route efficiencies can be enjoyed and potential for back haulscan be achieved. Also, if the trailer is not full because of timeconstraints, more time on the route will be enjoyed and more stopsplaced on the route because time will not be lost collecting emptycases.

The current mode of handling cases have a per unit distribution expensewhich can be drastically reduced. Based on simple arithmetic, it hasbeen estimated that the improvement might be as much as 30%.

In addition to the problems associated with transporting and shippingwith cases as described above, the production of the individual plasticcontainers widely used in the dairy industry is another area requiringimprovement, e.g. reduced production cost. A typical milk productionfacility will manufacture or purchase millions of these containers peryear. A cost savings of one-cent in material resin cost is significantwhen applied to the number of containers involved. As a result, therehas been much effort in the past to minimize the material costs withoutcompromising container integrity. It should be noted that the processingand distribution costs are much larger than the cost associated with theresin for a production facility. Thus, a need exists to produce acontainer with similar amounts of resin as used today (i.e.,thin-walled) while eliminating cases and all of the associated costsdescribed above.

Design efforts relating to containers for food have also focused onaesthetic appeal and consumer benefits. For example, a pitcher-likeconstruction which is easy to grasp and tilt and which provides for easypourability of the contained product may be desirable from a marketingperspective. Similarly, the container should incorporate non-dripcharacteristics and eliminate or reduce the potential for “glugging”caused by a lack of venting air into the container during pouring.

It would, therefore, be desirable to provide a container structure whichprovides for stackability and which eliminates the need for cases orshippers during bulk transport. It would be further desirable to providea container structure which provides enhanced strength, as well as theabove-mentioned consumer benefits, without adding to the material costsinvolved in its manufacture.

SUMMARY OF THE INVENTION

The present invention contemplates new and improved containers whicheliminate the need for cases or shippers and which provide increasedstrength for supporting static or dynamic vertical loads, therebyfacilitating stacking on pallets without the use of cases whilemaintaining costs for manufacture.

In accordance with the present invention, there is provided a containerfor a comestible product such as milk or juice that has a base with asubstantially planar region, a top surface with a substantially planarsurface and a pour spout, a sidewall interposed between the top surfaceand the base, and a structural load distributing feature for conveyingbearing loads from the substantially planar surface of the top surfaceto the base.

According to another aspect of the invention, the structural loaddistributing feature is integrally molded into the sidewall of thecontainer.

According to another aspect of the invention, the structural loaddistributing feature is provided in part by a sectional wraparoundlabel.

According to another aspect of the invention, the container ismanufactured of a plastic material having a weight to volume ratio ofapproximately fifty-five to seventy grams per gallon (approximatelyeighteen to twenty-four grams per liter).

According to yet another aspect of the invention, the pour spout isdisposed adjacent an edge of the container and the center of gravity isdisposed closer to the pour spout than the handle.

According to another aspect of the invention, a caseless, liquidhandling system includes plural similarly configured containers, apreselected number of containers held together as a unit with a firstflexible wrapping material, and multiple container units held in groupedand stacked array by a second flexible wrapping material.

A primary advantage of the invention resides in the cost savingsassociated with eliminating the use of cases to handle, store andtransport the containers.

Another advantage of the invention is found in the various consumerbenefits such as a pitcher-like shape with improved pourabilitycharacteristics.

Still other advantages and benefits of the invention will becomeapparent to those skilled in the art upon a reading and understanding ofthe following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangementsof parts, preferred embodiments of which will be described in detail inthe specification illustrated in the accompanying drawings which form apart hereof, wherein:

FIGS. 1A and 1B show industry standard cases for handling milk;

FIGS. 2A-2C illustrate delivery mechanisms for shipping large numbers ofcases;

FIGS. 3 and 4 illustrate the space requirements associated with shippingvia cases;

FIGS. 5A and 5B shows conventional destacking equipment for handling thecases;

FIG. 6 represents typical case washing equipment associated with today'ssystem;

FIGS. 7A-7C illustrate the filling and storage process encountered in adairy;

FIGS. 8A-8C show three versions of handling filled cases;

FIG. 9 is a representation of an automated material handling system;

FIG. 10 illustrates a trailer loaded with empty cases;

FIG. 11 Å is a perspective view of the first preferred embodiment and

FIGS. 11B-11D are views of alternative sidewall configurations;

FIG. 12 is another perspective view of the first preferred embodiment ofa container according to the present invention;

FIG. 13 is a sectional view of the container illustrated in FIGS. 11 and12;

FIG. 14 is an enlarged sectional view of the upper and lower spout ofthe embodiment illustrated in FIGS. 11-13;

FIG. 15 is a perspective of a grouping of four of the containersaccording to a preferred embodiment of the present invention;

FIGS. 16-18 are perspective views of a second preferred embodiment;

FIG. 19 is a rear elevational view of the second preferred embodiment;

FIG. 20 is a top plan view of the second embodiment;

FIG. 21 is a side elevational view taken generally from the right-handside of FIG. 19;

FIG. 22 is a front view of the second embodiment;

FIG. 23 is a bottom plan view of the second embodiment;

FIG. 24 is a perspective of a third preferred embodiment of the presentinvention;

FIGS. 25 and 26 are perspective views of a fourth preferred embodimentof the present invention;

FIG. 27 is a top plan view of the fourth embodiment;

FIGS. 28 and 29 are side elevational views of the fourth embodiment;

FIG. 30 is a rear elevational view of the fourth embodiment;

FIG. 31 is a front elevational view of the fourth embodiment;

FIG. 32 is a bottom plan view of the fourth embodiment;

FIG. 33 is a perspective view taken generally from the top and front ofa fifth preferred embodiment;

FIG. 34 is a perspective view of the fifth embodiment taken generallyfrom the bottom and rear;

FIGS. 35A and 35B are a perspective view of a sixth embodiment similarto the fifth embodiment;

FIG. 36 is an elevational view of a stack of containers according toeither the fourth or fifth embodiments;

FIGS. 37A-F are elevational and plan views of a sixth preferredembodiment;

FIG. 38 is a top plan view of four containers disposed in abuttingrelation to form a first unit;

FIG. 39 is a perspective of a pouring spout according to a preferredembodiment of the invention;

FIGS. 40A-F are perspective and plan views of various insertable spoutsconfigurations; and

FIGS. 41A and 41B are perspective views from the top, rear and thebottom, front regions of the container, respectively.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings wherein the showings are for the purposeof illustrating the preferred embodiments of the invention only and notfor purposes of limiting the same, the Figures show the present mannerof shipping, storage, and handling individual milk containers in cases(FIGS. 1-10 described above in the Background section), and a number ofembodiments of new containers according to the present invention thatadvantageously provide a caseless shipping system (FIGS. 11-40).

Referring to FIGS. 11-13, a container according to the present inventionis designated generally by the number 50 and may be a standard (3-literor 1 gallon) size container or any other size. Those of ordinary skillwill recognize that the container structures described herein arescalable to achieve virtually any size comprising a blow-molded plastic,although different manufacturing techniques may be used. Container 50comprises a top surface 52, bottom 54 and a wall 56 molded integrallytherewith. The top surface 52 and bottom 54 are of a generally diamondshape with an apex thereof coinciding with integrally molded handle 58.The handle proceeds from the top surface along the apex and terminatesbefore reaching the bottom.

The top surface 52 includes a stepped conformation having an uppersurface 60 and lower level deck portion 62 which is slightly verticallyrecessed from upper surface 60. An orifice 64 is formed in deck portion62 for egress of the liquid or other material contained in container 50.A pouring lip 66 extends upwardly from the deck portion 62 to form apouring spout 68 which is of generally diamond shape. A foil seal 70 isprovided for tamper resistance and detection as well as enhanced sealingcapabilities. A snap-on cap 72 cooperates with foil seal 70 and pouringspout 68. Seal 70 and cap 72 are of a diamond shape to simplifyautomation of the capping process during container filling. Orifice 64is generally sized to permit simultaneous egress of fluid and ingress ofair to prevent “glugging.” A secondary function of the large orifice 64is that it provides for easy ingress of fluid and/or powder mixture tothe container during reuse or initial filling of the container. Theorifice also permits the easy deployment of stirring utensils within thecontainer. It will be appreciated that when fluid is poured fromcontainer, fluid flows over one apex of the diamond shape of the spout.Cap upper surface 74 is aligned with container upper surface 60 when cap72 is snapped into place. This provides a large upper stacking surfacethat is substantially planar for increased stability and vertical loadsupport. A finger grip ledge 76 is provided on cap 72 to permit removalthereof. Pouring spout 68 extends outward in a direction opposite handle58 beyond wall 56 to form a cup guide 78, which functions to permit acup (not shown) to be correctly oriented to permit spill-free pouring.

According to one aspect of the invention, wall 56 is formed with anumber of structural load distributing or load transferring featuressuch as vertical ribs 80 which increase the sectional modulus of wall 56and prevent bending and/or buckling. Ribs 80 are preferably of a “V”shape in cross-section, with the apex of the “V” extending inward of thecontainer and are substantially continuous along the longitudinal heightof the container (see FIGS. 11-13). This structure permits theconstruction of manufacturing molds without the presence of undercuts,which are inefficient from a manufacturing standpoint. Preferably,vertical ribs 80 are incorporated into vertical surfaces of wall 56 inan effort to reduce the unbraced length of the wall and limitdeflections. For example, walls may otherwise be subject to buckling orcrimping as a result of vertical loads or forces while bulging may beassociated with hydrostatic forces. Thus, those wall regions which aretaller than four inches in a three liter container, for example, wouldbenefit from a change in the section modulus to limit deflections. Thisstructure will provide the container with the rigidity required forsupporting and transferring the load from one container to another in astacked relation—which the prior milk containers described in theBackground were unable to achieve.

A sectional wraparound label (not shown) may be incorporated to addfurther strength and structural integrity. For example, the wraparoundlabel can be used to purposely add a preload to the container and limitthe deflections. Alternatively, the structural load distributing featuremay be a series of diagonal reinforcements (FIG. 11B), offset ribs (FIG.11C), dimples (FIG. 11D), or combination of these features that areeffective in transferring forces from the top surface to the bottom ofthe container. These are preferred alternative ways to change thesection modulus and transfer vertical forces through the container. Thehandle, since it extends from the substantially planar top surface ofthe container, is also an important element in the load bearingarrangement.

Handle 58 is formed integrally with the container 50. One end of handle58 extends from upper surface 60 of the container to provide additionalsupport thereto. An opposite or lower end of handle 58 extends or mergesinto wall 56. A finger clearance hole 82 (FIG. 13) provides comfort fora large range of hand sizes of consumers. The finger receiving region isthus disposed adjacent the handle and preferably terminates beforereaching the base of the container. Handle 58 extends in a directionthat is directly opposite the apex of pouring spout 68 to provideself-centering of the spout. The construction of the handle alsofunctions in the handling of container arrayed into groups or containerunits as will be further explained below.

Container bottom 54 is provided with a pouring radius 84 which extendsinto wall 56. Pouring radius 84 is constructed to permit pivoting of thecontainer on a support surface when pouring without lifting is desired.This aspect of the invention is especially beneficial to users, i.e.,children or senior citizens, who have relatively little strength or arephysically challenged. Container bottom 54 is formed with a lowersurface 86 which is slightly concave (FIG. 12) when the container isempty, but which flattens out when the container is filled with liquidsuch as milk or fruit juice to form a generally horizontal surface. Aswill be appreciated, lower surface 86, together with the upper surface60 of an adjacent container (not shown), cooperate such that verticalloads are evenly distributed among and across the container surfaces. Asshown in FIGS. 12 and 13, wall 56 extends to a slight recess 87 atcontainer bottom 54.

FIG. 14 is a sectional view of the pouring spout 68 according to thepresent invention. Pouring lip 66 includes a pouring edge 90 that curvessharply downward at its extremity to create an anti-drip spout. Edge 90is displaced outward slightly from the outermost surface of lower pourspout 92. This configuration prevents liquid from running down the frontof container 50. Cup guide 78 extends downward and inward from lowerpour spout 92 to facilitate proper orientation of the pour spoutrelative to a cup.

FIG. 15 illustrates a grouping of four containers 50 according to apreferred embodiment of the invention. It will be recognized that twoadjacent containers are disposed with their respective handles 58adjacent one another to form a combined carrying handle 96. On anopposite side of the container grouping, two more handles 58 aresimilarly situated to from a second combined handle when arrayed in thisfashion. Two carrying handles 96, each comprising a pair of adjacentcontainer handles 58 are provided on opposite sides of the grouping topermit easy handling thereof. Of course, other numbers of containers(e.g., six containers which may be preferred for brick-like stacking ona pallet) can be grouped together to form a unit and the handlesoriented in a different manner such as at the corners of the group unit.

The four to six containers comprising the grouping unit are heldtogether with a first flexible material, preferably a shrink wrapthermoplastic 98. As can be seen in FIG. 15, a large combined uppersupport surface 100 is provided by the respective upper surfaces 60 ofthe containers 50. The first flexible material holds the individualcontainers in a desired orientation that is stable and capable of beingpositioned into a layer of units that define a first level of a stackedarray.

Each of the containers in the grouping shown in FIG. 15 are providedwith a flip top 110 which may be hinged to the container 50 usingsuitable means. Flip top 110 may be equipped with a recess or projectionfor engaging the pouring spout (not shown in FIG. 15). It will berecognized that the flip top 110 provides an extension of the topsurface 60 such that a load imposes on the top surface of the containergrouping is more evenly distributed and supported by a substantiallyplanar surface.

FIG. 16-23 show a second preferred embodiment of the invention that hasmany similarities to the embodiment described above in conjunction withFIGS. 11-15. Accordingly, the differences will be emphasized here andidentified by new numerals. For example, at least one of the structuralload distributing ribs or flutes is a continuous flute 112 that proceedsthrough the substantially planar surface of the top surface and downopposite sides of the container toward the base. Preferably this fluteis situated between the pour spout and the handle. In addition, the topsurface is modified to have a slight arch 114 thereto which is effectivein transferring the forces from the top surface to the base. Additionalflutes or ribs 116 are also provided in the top surface in the archregion and terminate in the upper portion of the container. The pourspout area is also modified, eliminating the flip top (FIG. 15) and thediamond-shaped cap (FIG. 11A), with a more conventional replaceable pushon, screw-off type cap 118, also known as a snap cap. As is evident,however, the screw-on cap is located so that it can serve as a part ofthe top surface (FIG. 22), particularly the substantially planarsurface, for transferring loads from containers stacked on top thereof.FIG. 18 illustrates that the bottom or base of the container is alsomodified relative to that shown in FIG. 12. It still serves, however, todefine a substantially planar surface 120 that transfers loads to a nextadjacent layer of containers, a pallet, or the like.

FIG. 24 illustrates a container 130 according to another preferredembodiment of the invention. Container 130 is shown in a verticalorientation with a spout 132 and cap 134 its top 136. Container 130includes a stacking wall 138 which permits the container to be stackedin a horizontal orientation. That is, container 130 will be laid on itsside in during shipping and warehouse storage. Stacking wall 138 isprovided with protrusions 140 and depressions 142 which permit stackingof the containers in a brick-like fashion. It will be appreciated that asimilar stacking wall is provided on the container opposite theillustrated one but is hidden from view in FIG. 24. The protrusions arereceived in the depressions and provide a horizontal stability to thestacked assembly. This embodiment incorporates a large recessed handle144 which may or may not include a finger hole (not shown). In thisembodiment, ribs are not provided owing to the shallow construction ofthe container when it is laid on its stacking wall 138 since only shortside walls 146 are present, ribs or flutes are not needed to provide therequired structural rigidity and stability. A pouring radius 148 is alsoprovided near the bottom 150 of container. This construction isadvantageous for containing and dispensing food products that are notliquid in form.

FIGS. 25-32 illustrate yet another preferred embodiment that issubstantially identical to that described with reference to FIG. 24.Accordingly like numerals will refer to like elements and new numeralswill identify new elements. The most noticeable addition are thestructural load distributing features comprising a series of verticallyspaced horizontal ribs or flutes 160 that transfer loads when thecontainers are stacked one on top of another. In this particularembodiment, the ribs are circumferentially continuous and generallyequi-spaced along the container, although it will be appreciated thatother arrangements may be used without departing from the scope andintent of the subject invention. Moreover, the curved wall 162 justbeneath the spout is more apparent in this embodiment to facilitatereceipt over the lip of a cup (not shown): The handle is againintegrally formed with the remainder of the container and forms a fingerreceiving opening 164 in the container. Features such as the radius 148,the curved wall 162, and an enlarged spout that provides an anti-glugfunction as well as a no-drip function are desirable consumer orientedattributes.

A fifth preferred embodiment is shown in FIGS. 33 and 34. Like the sixthembodiment of FIGS. 35A and 35B, and a related embodiment of FIGS.37A-F, this container is intended to transport larger amounts of milk orfruit juice while taking advantages of the caseless container conceptdescribed above and hereafter. These embodiments utilize a containerstructure that is in the form of a rectangular prism, generallyreferenced by the numeral 200. The container is formed of two sideportions 202, which are formed integrally with a center section 204. Theside sections 202 and center section 204 comprise a fluid containingvolume for containing liquid therein. Handle 218 is formed integrallyconnecting side sections 202. Center section 204 is formed with a recess208 for housing a pivotable spigot or tube 206. The spigot is pivotablyconnected to the container in a known manner. Side walls 212 of thecontainer are formed with a number of rib elements 210 for structuralreinforcement thereof. The ribs 210 also improve the stackingcharacteristics of the container as will be explained below. In theembodiment of FIGS. 33 and 34, additional ribs 216 are provided alongthe center section and are oriented in the opposite direction from theribs 210, i.e. in the vertical direction along the sidewalls and in ahorizontal direction along the upper and lower walls. Moreover, FIGS.35A and 35B demonstrates how the protrusion and depression feature mayalso be incorporated into the larger containers to aid in stacking in abrick-like fashion (FIG. 36). It will also be understood that a shrinkwrap may be used with this embodiment for holding the spigot in placeand for purposes of cleanliness.

FIG. 36 shows a stacking arrangement for these types of containers. Thedimensions of the rectangular prism 200 are selected such that theheight of the container is preferably twice the width and depth of thecontainer. This construction lends itself to the stacking arrangementillustrated in FIG. 36. Containers A, B, and C in FIG. 36 are laid alongtheir sides 210. Not shown in FIG. 36 are three (3) other containerswhich are beneath containers A, B, and C and also laid along their sides210. Containers D and E are oriented such that they stand upright withhandles 218 oriented on top of a container. The stacking conceptillustrated in FIG. 36 thus permits a compact grouping unit of eightcontainers which may be held together using a flexible wrapping materialsuch as a shrink wrap thermoplastic as was explained above. It will berecognized that handles 218 are oriented to permit easy carrying of thegrouping unit illustrated in FIG. 36. It will also be recognized thatthose containers B and C, and the containers disposed beneath them (notshown), will be oriented such that their respective handles aredisplayed or oriented outward of the unit grouping and, thus, willprovide additional handles for carrying or lifting the unit illustrated.

FIG. 38 is a plan view similar to FIG. 15 that illustrates how a groupof containers can be grouped together in a unit and the handlesadvantageously situated to aid in lifting or transporting the containersas a unit. For example, as disclosed in FIG. 15 the first flexiblewrapping material only extends about the lower portion of the abuttingcontainers. This leaves access to the handles so that the containers canbe easily manipulated as a unit. In FIG. 38, the handles will be locatedat each corner of the arrayed containers and the pouring spouts aregrouped at the center of the unit. Of course, different numbers ofcontainers and different orientations can be used for different purposesand without departing from the scope and intent of the invention.

FIG. 39 illustrates a pouring spout according to another preferredembodiment of the present invention. Like the embodiment shown in FIG.1, this embodiment incorporates a deck portion 222 on which is located apouring lip 226 extending upward therefrom. Lip 226 forms a pouringspout 228. In this embodiment, a pouring guard 260 is provided on thepouring spout. Guard 226 is provided with a narrow diamond-shapedaperture 262 which permits egress of the liquid or other materialcontained in the container. Guard 260 provides for a more narrow streamof liquid than would be provided by pouring spout 228 alone.

FIGS. 40A-F illustrate a variety of removable pouring inserts that maybe incorporated into the pour spout. FIGS. 40A and 40B show a key-shapedopening 270 and a vent or anti-glug opening 272 diametrically oppositetherefrom. A droplet-shaped opening 274 is embodied in FIGS. 40C and 40Dwhile a generally U-shaped opening 276 is incorporated into theembodiment of FIGS. 40E and 40F. In each, the generally planar surface278 has a taper that allows any liquid that is spilled over the edge ofthe pour opening to drain into the vent opening when the container isoriented in its upright, vertical position. The removable nature of thepouring inserts allows the consumer to remove the insert and refill thecontainer, if desired.

FIGS. 41A and 41B illustrate yet a further embodiment which findsapplication in larger containers such as two and one-half, three, andfive gallon sizes. It includes a vent cap 280 located adjacent the topsurface and ribs 282 in the sidewall for load transfer to the bottomsurface. As best illustrated in FIG. 41B, a dispensing nozzle 284receives one end of a dispensing tube 286 and the other end of the tubeis frictionally engaged by a tube holddown 288 defined by offset flanges290 that extend from the front wall of the container. The bottom surfacealso preferably includes a slight taper from the domed feet 292 towardthe dispensing nozzle to aid in dispensing product from the container.

A differently configured container having a large, wide top and bottomsurface to distribute the stacking load along the structurally desirablelocations such as the cap and handle may be developed using the featuresand attributes of the invention. Structural ribs that run perpendicularto the parting line can be placed at critical locations along thehorizontal, top surface to resist vertical, plastic deformation andbending. The vent tube, cap and large, structural handle were designedto handle the load in parallel to the parting line. The top and bottomsurfaces have been designed to nest in a manner to allow stress fromstatic and dynamic loads to be distributed to the sidewalls.

Vertical surfaces are provided with molded, structural ribs to providean increased section modulus along the member and provide improvedresistance to bending moments, deflections and buckling than isavailable in the presently used milk container. The ribs also act ascolumns to distribute loads from the top of the container to the bottomof the container. The ribs may be molded to have a “V” or fluted shapedcross-section to permit the use of molds without undercuts therein.Structural tests conclude that the stress is transmitted through thefootprint of the above case through the desired crown and down the sidesof the container.

A structural label may also be used to add strength to the container.The structure may operate as a pressure vessel and/or a static structureto support loads typically experienced during shipping and distribution.Cap and foil seals may be in incorporated to resist leakage and maintaininternal pressures. The containers will be shrink-wrapped in cases offour, six, or other appropriate number, for example, which providesstructural support and a unitized method for handling groups ofcontainers through a distribution network. Thereafter, the units arearrayed and stacked into larger handling groups such as on a pallet andwrapped by a second flexible member, e.g. another plastic wrappingmaterial, to form a larger shipping or transport group that can behandled in the same general manner as stacks of cases. The containerscan be stacked five or six high—just as the cases are presentlystacked—because of the ability to transfer loads effectively thoroughthe container without cases. The overall cost of manufacturing,cleaning, handling, storage, etc. of cases as described above iseliminated.

Structural tests indicate that the shrink-wrapped cases have a decreasein the column deflections by a factor of three. The containers weredynamically tested on a vibratory table to stimulate the dynamicsituation which occurs during handling and truck transport. Pallets areusually handled with motorized fork trucks which load the trucks.Vibration testing was conducted on fork truck and trucks in transport.These results were utilized in the dynamic laboratory testing. It wasobserved that the columnar effect that is developed in the palletconfiguration allow the degrees of freedom similar to a building duringan earthquake. These degrees of freedom allow the pallet to act as aunit; yet flex and move under loading to prevent detrimental stressconcentrations which can negatively impact the structural integrity ofthe cases and containers.

A diamond shaped pouring spout may be included and is of a large enoughdimension to permit venting back into the container to prevent“glugging” and to prevent dripping. A front surface of the container maybe formed to include a large radius aligned with the spout to permit arocking action which allows the container to be tilted easily withoutlifting from the support surface. The spout may be formed with a recessthereunder for placing a glass or cup and to minimize spills.

The group of stacked containers is then broken down into the individualunits by removing the second wrapping material. To aid in its removal,the second flexible material may incorporate a tear strip or the likeinto the material to allow easy removal of the plastic wrapping.

The invention has been described with reference to the preferredembodiments. Obviously, modifications and alterations will be apparentto those of ordinary skill upon a reading and understanding of thespecification. For example, the preferred material of construction is afood grade plastic such as a high density polyethylene (HDPE) althoughalternative materials that comprise a plastic, at least in part, couldbe used. The invention is intended to include all such modifications andalterations.

1. A container used in caseless shipping of a product, such as milk orjuice, the container comprising: a base having a substantially planarregion; a top surface having a substantially planar region parallel tothe substantially planar region of the base and having a pour spoutformed therein; a sidewall integrally formed with and extending betweenthe base and top surface, the sidewall enclosing an internal cavity incommunication with the pour spout; and a handle extending from thesidewall and defining a finger receiving region, the handle interposedbetween the base and top surface and integrally formed with the base,top surface, and sidewall.
 2. The container of claim 1 furthercomprising a structural load distributing feature formed therein forconveying bearing loads from the top surface to the base.
 3. Thecontainer of claim 2 wherein the structural load distributing featureincludes at least one rib formed in the sidewall and extending betweenthe top surface and the base.
 4. The container of claim 3 wherein thestructural load distributing feature extends in a continuous fashionalong the planar region of the top surface and the sidewall.
 5. Thecontainer of claim 4 wherein the structural load distributing feature isdisposed between the pour spout and the handle.
 6. The container ofclaim 1 wherein the sidewall includes a series of sidewalls and selectedones of the sidewalls include substantially planar regions for abuttingagainst substantially planar regions of sidewalls of like containers. 7.The container of claim 1 further comprising a rounded region along anedge portion of the base beneath the pour spout to facilitate pouring.8. The container of claim 1 further comprising a structural loaddistributing feature formed therein for conveying bearing loads from thetop surface to the base, the handle extending downwardly from the topsurface toward the base and the structural load distributing featuresubstantially aligned with the handle for transferring loads from thehandle to the base.
 9. The container of claim 1 further comprising aresealable lid operatively associated with the pour spout.
 10. Thecontainer of claim 1 wherein the container is a thin-walled plasticmaterial.
 11. The container of claim 10 wherein the container has aweight to volume ratio of approximately 55 to 70 grams per gallon(approximately 18 to 24 grams per liter).
 12. The container of claim 1wherein the pour spout includes an air opening disposed in spacedrelation to a pour opening.
 13. The container of claim 1 wherein thecenter of gravity of the container is disposed closer to the pour spoutthan to the handle to facilitate pouring of liquid from the container.14. The container of claim 1 wherein the pour spout is disposed oppositethe handle adjacent an edge of the container.
 15. The container of claim1 wherein the container is formed at least in part of plastic.
 16. Ahandling system comprising: plural similarly configured containers, eachincluding a substantially planar top surface, a substantially planarbase and a sidewall interconnecting the top surface and the base; apreselected number of containers being disposed in contiguousrelationship and held together as a unit with a first flexible wrappingmaterial; and container units being grouped together and stacked on topof one another for transport, the container units being held in groupedand stacked array by a second flexible wrapping material.
 17. Thehandling system of claim 16 wherein the containers each include a handledefining a finger receiving region.
 18. The handling system of claim 17wherein at least two handles of contiguous containers are disposedadjacent one another to facilitate handling of the unit of containers.19. The handling system of claim 17 wherein the handles are disposed atouter corner regions of the unit to facilitate handling thereof.
 20. Thehandling system of claim 16 wherein the containers hold a liquid. 21.The handling system of claim 16 wherein each container is formed atleast in part of a thin walled plastic material.
 22. The handling systemof claim 16 wherein the sidewall includes plural sidewalls.
 23. Thesystem of claim 16 wherein at least one of the sidewalls of eachcontainer includes a structural load distributing feature formed thereinand extending between the top surface and base for adding strengththereto for stacking purposes.
 24. The system of claim 16 furthercomprising a tear strip associated with the second wrapping material forselectively separating the container units from the grouped and stackedarray.
 25. The container system of claim 16 wherein each containerincludes a pour spout disposed opposite the handle and adjacent thejuncture of contiguous sidewalls, the containers that form a unitarranged so that the pour spouts are disposed inwardly of the group ofcontainers and the handles of each container are disposed along aperiphery of the unit.
 26. The container system of claim 16 wherein theunits of containers are stacked at least five levels high.
 27. Thecontainer of claim 16 further comprising wherein the units of containersare oriented in different arrays along each level.